Weaving with effect from orientation of high and low pile



Jan. 21, 1958 c. H. MASLAND 2ND 2,820,483

WEAVING' WITH EFFECT FROM ORIENTATION OF'HIGI-I AND LOW PILE Filed Dec.23, 1953 5 Sheets-Sheet 1 ATTORNEYS.

Jan. 21, 1958 c. H. MASLAND 2ND 2,820,433

WEAVING WITH EFFECT FROM ORIENTATION OF HIGH AND LOW FILE 5Sheets-Sheet- 2 Filed Dec. 25, 1953 INVENTOR C/iar/es #Masim dZaal.

ATTORNEYS r c. H. MASLAND 2ND 2,820,483

Jan. 21, 1958 WEAVING WITH EFFECT FROM ORIENTATION OF HIGH AND LowiPILEFiled Dec. 23 1955 v 5 Sheets-Sheet 3 INVENTOR /iar/es flw/znzCZ/zcZATTORNEYS.

' Jan. 21, 195.8 c. H. MASLAND 2ND 2,820,483

WEAVING WITH EFFECT FROM ORIENTATIQN OF HIGH AND LOW FILE 5 Sheets-Sheet4 Filed Dec. 23, 1953 nUIOI I'u IGIOIOIG- IGIGIIIO- halo-ow :vIuIoI haln:

2 m vm m N A m M 5 Sheets-Sheet 5 INVENTOR 1 Jan. 21, 1958 WEAVING WITHEFFECT FROM ORIENTATION OF HIGH AND Low- FILE Filed Dec. 2;, 1953 UnitedStates Patent WEAVING WITH EFFECT FROM ORIENTATION OF HIGH AND LOW PILECharles H. Masland, 2nd, Carlisle, Pa., assignor to C. H.

Masland & Sons, Carlisle, Pa., a corporation of Pennsylvania ApplicationDecember 23, 1953, Serial No. 399,877

4 Claims. (Cl. 139-39) The present invention relates to weaving of pilefabrics, particularly carpets and rugs, having a plurality of pileheights in the same transverse row, and also to the mechanism employedand the fabric produced.

The present application is a continuation in part of my copendingapplication Serial No. 144,764, filed February 17, 1950, for WeavingWith Effect From Orientation of High and Low Pile, now abandoned.

A purpose of the invention is to secure variation in pile heightthroughout a carpet or rug or any portion thereof according to a contourpattern or according to a random distribution, the contour variation inpile height occurring in the same transverse row of pile projections,and the contour pattern or variation in pile height running through thecolor pattern, if any, independently of the color pattern, and extendingthrough areas of a single color in the color pattern.

A further purpose is to weave a pile fabric such as a carpet or rug overa set of wavy pile wires having the high and low points on therespective wires arranged according to a contour pattern or according toa random distribution.

A further purpose is to interpose two or more straight wires ofdifferent heights between wavy wires in weaving a pile fabric raisedover the successive wires.

A further purpose is to interpose a plurality of straight wires ofdifferent heights in between each pair of wavy wires, providing pileyarn from which the wavy wires can pull pile when they are withdrawn andpermissibly also providing uniform pile projections.

Further purposes appear in the specification and in the claims.

In the drawings 1 have chosen to illustrate one only of the numerousembodiments in which my invention may appear, selecting the form shownfrom the standpoints of convenience in illustration, satisfactoryoperation and clear demonstration of the principles involved.

Figures 1 to 4, inclusive, are diagrammatic views showing the weaving ofa fabric in accordance with the invention, Figures 3 and 4 beingenlargements respectively of Figures 3 and 4 to illustrate the weavepreviously produced.

Figure 5 is a fragmentary sectional perspective showing the wire setwhich employs two straight wires between each pair of wavy wires inaccordance with the invention, the straight wires being of differentheights.

Figure 6 is a conventional warpwise weave diagram showing the weaveaccomplished with the wires of Figure 5.

Figure 7 is a perspective of a wire which may be employed as one of thewavy wires in the invention.

In the drawings like numerals refer to like parts.

Describing in illustration but not in limitation and referring to thedrawings:

In the prior art pile fabrics such as carpets and rugs have been wovenin which the pile in certain transverse rows varies in height because itwas woven over wavy wires, and permissibly a straight wire has beeninterposed between the wavy wires.

By the present invention, novel textured effects are obtained byinterposing two or more straight wires of different heights betweenadjoining wavy wires, and permissibly making one or more of the straightwires dominant over the wavy wires.

If the same pile Warp ends wholly or in part are raised over thestraight wires as over the wavy wires, it will be evident that the pileprojections raised over the straight wire immediately ahead of the wavywire will be converted to wavy pile projections when the wavy wire iswithdrawn from the fabric, whereas the pile projections raised over thewavy wire will become straight when the wavy wire is withdrawn. It isnot possible in this case to obtain predominant uniform ridges in thefabric, however, as only a single straight row of pile projectionsexists between wavy transverse rows. In accordance with the presentinvention, by placing two straight wires in adjoining relation, andusing such wires of different heights, it will be evident that even ifthe row formed over one of the wires is converted to a wavy row by thewithdrawal of a subsequent wavy Wire, the other adjoining straight rowor rows formed over straight wires is not thus affected, imparting arelatively strong and uniform feature to the pattern. Furthermore, sincethe adjoining straight wires are of diiferent heights, a masking effectis obtained by which the pile can in some cases overhang the low wavyloops, and likewise the straight loops formed when the wavy wire iswithdrawn can be dominated or masked by loops formed over a still higherstraight wire as desired.

It will further be evident that where different pile warp ends areraised over the different wires, either because several warps are usedin tapestry weaving or because a jacquard is employed in brusselsweaving, even more variety can be obtained, since one or more colors ofpile formed over straight wires which are relatively low can bepartially masked by colors of pile formed over relatively high straightwires between wavy pile.

As far as the Wavy wires are concerned, it will be understood that therelative high points on successive wires will be displaced laterallyaccording to a contour effect or according to random distribution asdesired.

The present invention is concerned with the use of noncutting wires,both for the wavy wires and for the straight wires, to produce uncutpile loops.

For many purposes it will be sufficient to employ two straight wires ofdifferent heights between each pair of wavy wires, but the number ofstraight Wires in between any pair of wavy wires may vary with theconditions, being suitably two, three, four, five, etc., as desired. Infact any number of straight wires of different heights may be usedbetween the wavy wires which does not destroy the contour pattern effectcreated by the wavy wires.

The weave employed may be of any suitable character, Figures 1 to 4illustrating a conventional Wilton weave to which the invention has beenapplied.

In this weave, binder warps 70 and 71 are withdrawn from a binder warpbeam 72 through a reversing and tensioning device 73. Binder warp 70 ismanipulated by binder warp heddle 74 and binder warp 71 is manipulatedby binder warp heddle 75. Stutfer warp 77 is taken from stulfer Warpbeam 76 over tensioning device 73' and is manipulated by stuifer warpheddle 78. It will be evident, of course, that any desired number ofstuffer warps may be employed.

Pile warps 80 and 81 are respectively taken from creel frames 82 and 83through tensioning devices, not shown and manipulated through lingoeheddle 84 and 85 by any suitable-mechanism such as a jacquard to raiseand lower asaaesa the pile warps of the appropriate color at the properposition laterally of the fabric. While only two pile warps are shown,it will be understood, of course, that any desired number will beemployed in multicolor pattern weaving, and that the invention is notlimited to antiperticular number of pile warps of different colors.

A reed is shown at 86.

Startin" with the first step in the cycle as shown in Figure 1, binderwarp heddle 75, stuffer warp heddle 73 and lingoe heddles and 85 are alldown, while binder warp heddle 74- is in the upper position. A shot ofweft fl? is taken under binder warp and over binder warp 71, overstutfer warp 77 and over pile warps 80 and 81. The beat of reed S6completes the first step.

At the beginning of the second step as shown in Figure 2, the binderwarp heddles 74 and 75 are reversed, stuffer warp heddle 755 is raisedand lingoe heddle 84 is fully raised as the color pattern may requireand lingoe heddle 85 is raised half Way as the color pattern mayrequire. Wire is inserted under pile warp and above both binder warps,the stutter warp and pile warp S1. A shot of weft 99 is taken under bothpile warps, under binder warp 71, under stutter warp 77 and over binderwarp .70 and the lay is beaten up.

At the beginning of the third step, the stuffer warp heddls 723 isbrought down, While the binder warp heddles remain in the same positionand lingoe heddles 84- and are brought down. A shot of weft 9.1. istaken under binder warp 7?. and over binder warp 7t), stutfer warp 77and pile warps 8d and 81. The lay is beaten up.

At the beginning of the fourth step, as shown in Fig ure 4, binder warpheddles 7 and 75 are reversed, stulfer warp heddle 78 is raised, lingoeheddle 84 is fully raised as the color pattern may require, and lingoeheddle 85 is raised half way as the color pattern may require. Wire 92is inserted beneath pile warp 8d and above pile warp 31, stutter warp 77and both binder warps, and a shot of weft 93 is taken over binder warp7i and beneath both pile warps, stuifer warp 77 and binder warp 70, Thelay is beaten up.

It will be evident that in this single cycle two wires 8t; 92 areinserted, and as the cycles continue successive wires will be introduceduntil the full wire set has been inserted, after which the wires arewithdrawn, as well known in the art. Since all of the wires employed arenoncutting wires, nothing unusual will happen during Withdrawal until awavy Wire is withdrawn, in which case it will pull down the loops of thenext preceding row of pile proiections in which the same pile warp endsare raised in the pile.

Figure 5 illustrates a sequence of wires which are repeated over andover again in the set of wires. Wire 88 is a straight wire and next toit is another straight wire 92 which is here shown higher than Wire 38and desirably somewhat higher than the highest point on the wavy wire fil which adjoins. Following wavy wire 94 is straight wire 3' which may ormay not be of the same height as straight wire 38. Then follows straightwire 96, which may or may not be of the same height as straight Wire 92,but desirably will be of a different height from straight wire as shown.T he next in the sequence is wavy wire 9]. Wavy wires 9d and 97 havetheir high and low points differently displaced laterally to create acontour pattern.

When wavy Wire @4 is withdrawn as may be seen from Figure 6, it pullsdown the adjoining loop to a lower height if that loop is formed fromthe same pile Warp end.

Figure 7 illustrates a wire constructed in accordance with theinvention, having a head 98 of any suitable character to be engaged bythe Wire mechanism, and having low steps ii'lil within the shed.Intermediate steps 101 and high steps 162 within the shed are provided24 intervals along the length of this wavy wire, at the top surface, inaccordance with the contour pattern or random r a g m T e edges arsmooth as n co entional practice. Each successive wire has the highpoint and preferably also the low and intermediate points located atdifferent positions along the length of the wire, for example, atdifferent distances from the end of the wire and also, if desired,closer together or farther apart, depending upon the contour pattern.

The low and intermediate portions of the wire are connected by slope 103in the direction of withdrawal, while the intermediate and high portionsare connected by slopes 104 in the direction of withdrawal. The anglesof the slopes over which the loops are pulled when the wire is withdrawnare matters of importance, and should be gradual, preferably notexceeding 15 and most desirably not exceeding 10 with respect to thelongitudinal axis of the wire.

In Figure 6 loops 105 are raised over wires before the pattern changeand loops 106 after the pattern change by the jacquard or the like,

In view of my invention and disclosure variations and modifications tomeet individual whim or particular need will doubtless become evident toothers skilled in the art, to obtain all or part of the benefits of myinvention without copying the process and fabric shown, and I,therefore, claim all such insofar as they fall within the reasonablespirit and scope of my claims.

Having thus described my invention what I claim as new and desire tosecure by Letters Patent is:

1. The method of weaving a pile fabric, including binder warps, ,stufferwarps, pile warps and wefts, which comprises interweaving various warpsand wefts into a fabric, raising pile warps over a first noncutting pilewire having a plurality of heights on its upper surface throughout thelength which is in the fabric before withdrawal, next raising pile warpsover a second noncutting pile wire which is straight on its uppersurface throughout the length which is in the fabric before Withdrawal,next raising pile warps over a third noncutting pile wire which isstraight on its upper surface throughout the length which is in thefabric before withdrawal but is of a difierent height from the secondpile wire, subsequently raising pile warps over a fourth noncutting pilewire having a plurality of different heights on its upper surfacethroughout the length which is in the fabric before withdrawal andhaving different heights at the same lateral position in the fabric fromthose on the second pile wire, at least some of the pile warps raisedover the first pile wire also being raised over one of the second andthird pile wires, nd sub equently thd a ng the Wir s s y in the ordernamed, whereby the withdrawal of the first pile wire converts the pileprojection formed from one of the second and third pile wires into wavypile projections while the pile projections formed over the other of thesecond and third pile wires are not influenced by the withdrawal of thefirst pile wire.

2. The method of claim 1, in which the height of one of the second andthird pile wires exceeds the height of the low portions of the firstpile wire, whereby masking of low loops can occur when the pile wiresare withdrawn.

3. The method of weaving a pile fabric, including binder warps, stufferwarps, pile warps and wefts, which comprises interweaving the variouswarps and wefts into a fabric, raising pile warp ends over successivenoncu ting pile wires including in sequence a first noncutting pile wirewhich is wavy on the upper surface over which the pile warps are raised,a plurality of straight noncutting pile wires of different heights atleast one of which is higher than the low portions of the first pilewire, and then a second noncutting pile wire which is wavy on its uppersurface over which the pile warps are raised, but which has its highpoints at different lateral locations from those on the first pile Wire,the high points of sucCBSsive Wavy pile wires being arranged accordingto a contour pattern effect, .at least some of the pile warp nds r iseder the fourth pile wire ei g rais er one of the second and third pilewires, and withdrawing the successive pile wires from the fabric in theorder named, whereby a contour pattern is created running through thefabric, certain pile warp ends forming pile projections over one of thesecond and third pile wires being converted to wavy pile projections andpile warp ends over the other of the second and third pile wires formingstraight pile projections.

4. The method of weaving a pile fabric including binder warps, stufierwarps, pile warps and wefts, which comprises interweaving the variouswarps and wefts into a fabric, raising selected pile warps from aplurality of pile warps of dilferent colors in accordance with a colorpattern over successive noncutting pile wires including in sequence afirst noncutting pile wire which is wavy on the upper surface over whichthe pile warps are raised, a plurality of straight noncutting pile wiresof difierent heights and then a second noncutting pile wire which iswavy on its upper surface over which the pile warps are raised, butwhich has its high points at ditferent lateral locations from those onthe first pile wire, the high points of successive wavy pile wires beingarranged according to a contour pattern effect, and certain of the pilewarp ends raised over the fourth pile wire also being raised over one ofthe second and third pile wires, and withdrawing the successive pilewires from the fabric in the order named and thus creating a contourpattern running through the color pattern of the fabric, the withdrawalof the fourth pile wire converting one of the rows of pile projectionsformed over the second and third pile wires into wavy pile projectionsand leaving the other of said rows of pile projections as straight pileprojections.

References Cited in the file of this patent UNITED STATES PATENTS1,714,104 Pearsall May 21, 1929 2,179,375 Matthews Nov. 7, 19392,516,465 Jackson July 25, 1950 2,532,903 Groat Dec. 5, 1950 2,590,608Groat Mar. 25, 1952 2,670,013 Groat Feb. 23, 1954 2,713,877 Jackson July26, 1955 FOREIGN PATENTS 273,409 Great Britain July 6, 1927 916,349France Aug. 19, 1946

